72
Installation manual 405 Standardized gear units Hansen Industrial Transmissions nv IM_405
Installation manual
405
Standardized gear units
Hansen Industrial Transmissions nv IM_405
Copyright and contact data
Copyright Hansen Industrial Transmissions NV
This document or parts thereof may not be reproduced, stored in a retrieval system, nortransmitted, in any form nor by any means, electronic, mechanical, photocopying, recording, norotherwise, without the prior written permission of Hansen Industrial Transmissions NV.
This document could contain technical inaccuracies or typographical errors. Hansen IndustrialTransmissions NV reserves the right to revise the content of this document from time to timewithout the obligation of Hansen Industrial Transmissions NV to notify any person of such revisionor change.
Details and values given in this document are average values and have been compiled with care.They are not binding, however, and Hansen Industrial Transmissions NV disclaims any liability fordamage or detriments suffered as a result of reliance on the information given herein or the use ofproducts, processes or equipment to which this document refers. No warranty is made that the useof the information or of the products, processes or equipment to which this document refers will notinfringe any third party's patents or rights. The information given does not release the user frommaking their own experiments and tests.
Contact data
www.sumitomodrive.com
Hansen Industrial Gearbox Services
Terelststraat 208
BE-2650 Edegem
Belgium
E-mail: [email protected]
24/7 SERVICE HOTLINE
Tel.: +32 3 450 12 34
2
Contents
1 Customer data sheet................................................................................7
2 Manual Disclaimer................................................................................... 9
3 About this document.............................................................................. 103.1 Function of the document.......................................................................................................... 103.2 Language...................................................................................................................................103.3 Illustrations.................................................................................................................................103.4 Use of steps, lists and titles in this document............................................................................ 103.5 How to use this document..........................................................................................................103.6 Warnings, cautions and notes used in the document................................................................ 103.7 Related documents....................................................................................................................113.8 Storage of this document and the related documents............................................................... 123.9 Abbreviations............................................................................................................................. 123.10 Customer support...................................................................................................................... 12
4 Description............................................................................................. 134.1 Intended use.............................................................................................................................. 134.2 Type plate.................................................................................................................................. 13
4.2.1 Type plate.................................................................................................................. 134.3 Signs in the documentation and on the gear unit.......................................................................144.4 Description of the lubrication of the gear unit.............................................................................17
4.4.1 Function of lubrication................................................................................................174.4.2 Splash lubrication.......................................................................................................184.4.3 Force-feed lubrication................................................................................................ 18
4.5 Breather plug............................................................................................................................. 184.6 Cooling system.......................................................................................................................... 184.7 Direction of rotation of the shafts............................................................................................... 19
5 Safety.....................................................................................................205.1 Restrictions................................................................................................................................ 205.2 Approved installation engineer...................................................................................................205.3 General safety instructions........................................................................................................ 205.4 Safety instructions for installation.............................................................................................. 215.5 Special safety instructions (backstop)........................................................................................215.6 Noise and vibrations.................................................................................................................. 215.7 Partly completed machine..........................................................................................................215.8 Instructions in case of a fire....................................................................................................... 215.9 Warranty.................................................................................................................................... 22
6 Transport................................................................................................236.1 Off-site transport........................................................................................................................ 236.2 On-site transport........................................................................................................................ 23
6.2.1 Lift the gear unit......................................................................................................... 23
Contents
IM_405_002_EN 3
7 Storage.................................................................................................. 267.1 General storage instructions......................................................................................................267.2 Indoor storage for maximum 1 year...........................................................................................267.3 Extended storage outdoors for maximum 2 years (extended outdoor storage).........................267.4 Extended storage indoors for maximum 5 years (extended indoor storage)............................. 27
8 Installation..............................................................................................288.1 Maximum time between installation and commissioning........................................................... 288.2 Remove the packaging material................................................................................................ 288.3 Installation instructions for parts that are not part of the gear unit.............................................288.4 Do a check for corrosion of internal parts of the gear unit......................................................... 288.5 Install the couplings................................................................................................................... 28
Prepare.......................................................................................................................................29Apply the sealing paste.............................................................................................................. 29Install the coupling hubs.............................................................................................................29Remove unwanted sealing paste and apply paint......................................................................30
8.6 Install parts that give external loads to the gear unit..................................................................308.7 Install gear units with a backstop...............................................................................................308.8 Align the gear unit......................................................................................................................31
8.8.1 Align the gear unit in the horizontal plane..................................................................318.8.2 Align the LSS (multi-stage)........................................................................................ 318.8.3 Align the LSS (single stage).......................................................................................318.8.4 Align the HSS.............................................................................................................32
8.9 Attach the gear unit with the bolts (solid shafts)........................................................................ 32Attach the gear unit.................................................................................................................... 32Install the safety cover................................................................................................................32
8.10 Attach the gear unit (hollow shafts)............................................................................................328.10.1 Install the shrink disk..................................................................................................328.10.2 Install the shaft with keyway connection.................................................................... 348.10.3 Install the torque arm................................................................................................. 37
8.11 Install a ground connection........................................................................................................388.12 Install the lubrication system......................................................................................................38
8.12.1 General instructions for the lubrication system.......................................................... 388.12.2 Instructions for force-feed lubrication (integrated pump)........................................... 398.12.3 Instructions for force-feed lubrication (pump with a motor)........................................398.12.4 Instructions for force-feed lubrication (pressure lubrication)...................................... 39
8.13 Fill the gear unit with gear oil..................................................................................................... 398.13.1 Select the gear oil...................................................................................................... 398.13.2 Add gear oil (gear unit with motor base).................................................................... 408.13.3 Add gear oil (QHR.4, QVR.3 and QVR.4)..................................................................408.13.4 Measure the gear oil level..........................................................................................408.13.5 Add gear oil (all gear units)........................................................................................ 418.13.6 Drain gear oil..............................................................................................................41
8.14 Add grease to the lubrication points for grease......................................................................... 418.14.1 Select the grease type............................................................................................... 418.14.2 Add grease.................................................................................................................41
8.15 Install the oil-to-air cooler...........................................................................................................428.16 Install the water cooling............................................................................................................. 42
8.16.1 Install the water cooling............................................................................................. 428.16.2 Install the oil-to-water cooler...................................................................................... 428.16.3 Install the cooling coils............................................................................................... 43
8.17 Installation instructions (heater).................................................................................................43
Contents
4 IM_405_002_EN
9 Commissioning...................................................................................... 449.1 Maximum time between commissioning and operation............................................................. 449.2 Do a check on the gear unit.......................................................................................................449.3 Start instructions (backstop)...................................................................................................... 449.4 Start instructions (heater)...........................................................................................................449.5 Start instructions (force-feed lubrication, pump with a motor)....................................................449.6 Start instructions (force-feed lubrication, integrated pump)....................................................... 459.7 Start instructions (drive group with a 2-speed motor)................................................................ 459.8 Instructions after commissioning................................................................................................45
10 Instructions for operation....................................................................... 4610.1 General instructions for operation..............................................................................................4610.2 Instructions (force-feed lubrication, pump with a motor)............................................................4610.3 Instructions (water cooling)........................................................................................................4610.4 Instructions (drive group with a 2-speed motor).........................................................................4610.5 Instructions if the gear unit does not operate more than 2 weeks............................................. 46
Operate the gear unit for 5 minutes each 2 weeks.....................................................................47Protect the gear unit with a volatile corrosion inhibitor...............................................................47
11 Removal of the gear unit........................................................................4811.1 General instructions for removal of the gear unit.......................................................................4811.2 Remove the gear unit (solid shafts, couplings)..........................................................................4811.3 Remove the gear unit (hollow shafts)........................................................................................ 48
11.3.1 Disconnect the gear unit from the torque reaction point............................................ 4811.3.2 Remove the shrink disk..............................................................................................4811.3.3 Disconnect the keyway connection............................................................................49
12 Care for the environment....................................................................... 51
13 Technical data........................................................................................5213.1 Dimensions and mass................................................................................................................5213.2 Materials of the gear unit........................................................................................................... 5213.3 Torque seal specification........................................................................................................... 5213.4 Paint specification......................................................................................................................5213.5 Corrosion protection by H.I.T.....................................................................................................5213.6 Position of the gear unit............................................................................................................. 5313.7 Ambient conditions for storage.................................................................................................. 5313.8 Misalignment of the LSS............................................................................................................5313.9 Misalignment of the HSS (couplings).........................................................................................5313.10 Bolt specifications (gear units with solid shafts).........................................................................54
13.10.1 Bolt specifications (single-stage, horizontal LSS)...................................................... 5413.10.2 Bolt specifications (multi-stage, horizontal LSS)........................................................5513.10.3 Bolt specifications (multi-stage, vertical LSS)............................................................ 57
13.11 Torque values for oil drain screw...............................................................................................5813.12 Shrink disk specifications (2-part shrink disk)............................................................................58
13.12.1 Lubrication................................................................................................................. 5813.12.2 Torque specifications................................................................................................. 59
13.13 Prestress specifications for the torque arm (hollow shaft)......................................................... 6013.14 Lubricants.................................................................................................................................. 61
13.14.1 General specifications for lubricants.......................................................................... 61
Contents
IM_405_002_EN 5
13.14.2 Additional gear oil specifications (heater).................................................................. 6113.14.3 Mineral gear oil and related grease........................................................................... 6213.14.4 Synthetic gear oil and related grease........................................................................ 63
13.15 Grease quantity at lubrication points for bearings......................................................................6413.15.1 Grease quantity type..................................................................................................6413.15.2 Grease quantity types Q1, Q2, Q3, Q6, Q7 and Q8.................................................. 6513.15.3 Grease quantity type Q4............................................................................................ 6613.15.4 Grease quantity type Q5............................................................................................ 6613.15.5 Grease quantity type Q9............................................................................................ 67
13.16 Grease quantity for lubrication points at labyrinth seals (LSS).................................................. 6813.16.1 Grease quantity type..................................................................................................6813.16.2 Grease quantity (single-stage)...................................................................................6813.16.3 Grease quantity (multi-stage).....................................................................................68
13.17 Grease quantity for lubrication points at labyrinth seals (HSS)..................................................6913.17.1 Grease quantity type..................................................................................................6913.17.2 Grease quantity (single-stage)...................................................................................6913.17.3 Grease quantity (multi-stage).....................................................................................70
13.18 Cooling water specifications...................................................................................................... 70
Contents
6 IM_405_002_EN
Customer data sheet
Customer References
NameProjectApplication
Hansen Industrial Transmissions References
Manufacturing NumberOrderGear Unit Type
Technical Specifications
AGMA Power Rating [kW]AGMA Torque Rating [kNm]Exact RatioInput Speed(s) constant [RPM]Input Speed(s) variable [RPM]Output Speed(s) constant [RPM]Output Speed(s) variable [RPM]Shaft ArrangementMotor Power [kW]Motor Torque [kNm]Service Factor on Motor PowerAbsorbed Power [kW]Absorbed Torque [kNm]Service Factor on Absorbed PowerDirection of Rotation (low speed shaft)Mass of the gear unit1 [kg]
ATEX Specifications
ATEX marking Gear unitATEX marking electrical systemCalculated minimum bearing lifetime [Hrs]
Paint
Corrosion category according to ISO12944-2Colour
Lubrication
Type of gear oilOil viscosity grade [ISO VG]Minimum temperature for theoil bath for start-up [ºC]
1
1 Estimated value, without gear oil, without drive package components
Customer data sheet
IM_405_002_EN 7
Lubrication
Maximum ambient temperature[ºC]Maximum continuous tempera-ture of the gear oil in the oilbath, during operation [ºC]Maximum peak temperature ofthe gear oil in the oil bath, dur-ing operation, [ºC]Grease type
Storage and protection
The gearbox is adequately treated for storage and corrosion protection up to2
1 year indoors
2 years outdoors
5 years indoors
2 The applicable value is marked with X
Customer data sheet
8 IM_405_002_EN
Manual DisclaimerThis Manual and its instructions and information do not purport to cover all details orvariations in the gear unit and do not claim to provide for every possible contingency metin connection with handling, installation, operation, or maintenance. Hansen IndustrialTransmissions nv does not make any representations, warranties or guarantees, expressor implied, as to the accuracy or completeness of the Manual. Users must be aware thatupdates and amendments will be made from time to time to the Manual. It is the user’sresponsibility to determine whether there have been any such updates or amendments.Neither Hansen Industrial Transmissions nv nor any of its directors, officers, employeesor agents shall be liable in contract, tort or in any other manner whatsoever to any personfor any loss, damage, injury, liability, cost or expense of any nature, including withoutlimitation incidental, special, direct or consequential damages arising out of or inconnection with the use of the Manual. The user and/or purchaser bears all risks. Shouldfurther information be desired or should particular problems arise which are not coveredsufficiently for the users’ and/or purchaser’s purposes, the matter should be referred to inwriting to Hansen Industrial Transmissions nv.
Warning: Read and understand all instructions and information prior to anyhandling including maintenance, installing or starting the gear unit. Failure tofollow instructions could lead to damage, serious injury, or death.
• Only qualified and trained personnel should be involved with the storage (includingtransport), commissioning, operation, installation (including removal), inspection,maintenance and repairs of this gear unit.
• Make sure all your personnel, operators of this gear unit have been professionally andadequately trained for safe working practices.
• Operators must wear adequate personal protective equipment.• Ensure all international, EU, national and local safety regulations and codes are
followed when handling, maintaining, installing (including all related actions) the gearunit.
• Verify the compatibility of the gear unit with the installation it is meant for.
2
Manual Disclaimer
IM_405_002_EN 9
About this document
Function of the documentThe document is only applicable for the "Hansen P4" gear unit, from here on in thedocument referred to as the gear unit.
The document is for approved installation engineers and gives the information that isnecessary to install and remove the gear unit.
LanguageThe original instructions of this document are in English. All other language versions aretranslations of the original instructions.
If there is any doubt, the English version of the document is binding.
IllustrationsIt is not always possible to show the configuration of your gear unit as in the certifieddrawing. The illustrations in this document show a typical setup. They are for instructionor description only.
Use of steps, lists and titles in this document• The steps in procedures have numbers (123) if the sequence is important.• The lists and steps with bullets (•) are used if the sequence is not important.• The lists with letters (abc) are used if the sequence is important.• In titles of sections, the part between brackets () shows to which type of gear unit or
component of the gear unit the section applies.
How to use this documentProcedure
1. Make sure that you know the structure and the contents of the related documents.2. Read the safety chapter and make sure that you know all the instructions.3. Do the steps in the procedures fully and in the correct sequence.
Warnings, cautions and notes used in the documentType Description Icon
Warning If you do not obey the instruc-tion, this can cause injury.
Caution If you do not obey the instruc-tion, this can cause damage tothe gear unit, to equipment orto property.
3
3.1
3.2
3.3
3.4
3.5
3.6
About this document
10 IM_405_002_EN
Type Description Icon
Note A note gives more data.
Related documentsDocument name Document code Target audience
General conditions of sale - • All personnel
Order acknowledgement OA_ • Approved installation engi-neers
Certified drawing • Approved installation engi-neers
Installation manual IM_ • Approved installation engi-neers
Maintenance manual MM_ • Approved maintenance en-gineers
Logbook • Approved installation engi-neers
• Approved maintenance en-gineers
Spare parts drawing • Approved maintenance en-gineers
Service manual of the lubrica-tion and cooling system
D_ • Approved installation engi-neers
• Approved maintenance en-gineers
3.7
About this document
IM_405_002_EN 11
Document name Document code Target audience
Drive package documentation • Approved installation engi-neers
• Approved maintenance en-gineers
Storage of this document and the related documentsThis document and the related documents are a part of the gear unit.
• Make sure that you keep the document and the related documents in a dry and cleanlocation.
• Make sure that the document and the related documents are available to allpersonnel.
AbbreviationsAbbreviation Description
H.I.T. Hansen Industrial Transmissions NVLSS Low-Speed ShaftHSS High-Speed Shaft
Customer supportProcedure
1. If more information is necessary, speak to H.I.T.2. Give the manufacturing number and gear unit type to H.I.T. Refer to the type plate.
3.8
3.9
3.10
About this document
12 IM_405_002_EN
Description
Intended useThe gear unit is a part of a machine.
Only use the gear unit for the application, ambient conditions, operation conditions andother conditions of use shown in the order acknowledgement.
Resonant vibrations may cause severe overloads on components which may be severaltimes higher than the nominal load. The responsibility for the vibration analysis whichincludes the total system of driver, gearbox, driven equipment, couplings, mountingconditions and sources of excitation rests with the owner of the installation. H.I.T. is notresponsible for system dynamics and related damage.
Type plate
Type plateThe type plate gives information about the gear unit.
A Manufacturing number
B Gear unit type
C Production number
D Nominal power rating at the HSS
E Nominal torque rating at the LSS
F Service factor
G Exact ratio (R: reduction, M: multiplication)
H Mass of the gear unit, without gear oil
I Input speed n1 (output speed n2)Input speeds n1/n1' (output speeds n2/n2')
4
4.1
4.2
4.2.1
Description
IM_405_002_EN 13
Variable input speed n1-n1' (variable output speed n2-n2')
J Type of gear oil
K Viscosity of the gear oil
L Minimum temperature for the oil bath for startup
M Maximum ambient temperature for which the viscosity of the gear oil is applicable
N Quantity of gear oil
O Grease quantity type
P Number of lubrication points
Q Grease type
Z Remarks
Note: The certified drawing shows more data:
• illustration of the gear unit type• connection diagrams• dimensions
Signs in the documentation and on the gear unitSign Description
Risk of hot surface
Protective clothing is mandatory.
Hearing protection is mandatory.
Read and understand the installation and maintenance manual beforeany handling.
Dipstick
Oil drain
4.3
Description
14 IM_405_002_EN
Sign Description
Magnetic
C
F Drain valve with hose coupling
Oil fill plug
Breather plug
Anti-humidity
Condensation drain
Lubrication point for grease
Lubrication point for grease at bearing
Lubrication point for grease at labyrinth seal
Direction of rotation: clockwise
Direction of rotation: counterclockwise
Description
IM_405_002_EN 15
Sign Description
Breather plug to prevent ingress of moisture
Level indicator
Gauge glass
Overflow
Inspection opening
P
Pump lubrication
Filter
Filter with mechanical contamination indicator
Filter with electrical contamination indicator
C
Temperature indicator
Temperature transmitter
Level switch
Flow switch
Description
16 IM_405_002_EN
Sign Description
Pressure switch
Pressure transmitter
bar
Pressure indicator
Pressure relief valve
Built-in backstop
Heater
Protection cap for bolt or nut
Hole for vibration sensor
Ground connection
ATEX
Description of the lubrication of the gear unit
Function of lubricationLubrication is necessary for these functions:
• To prevent metal-to-metal contact in gears and bearings• To decrease friction losses• To dissipate generated heat from the gears and the bearings• To prevent corrosion
4.4
4.4.1
Description
IM_405_002_EN 17
These parameters have an effect on the type of lubrication system for the gear unit:
• Gear speed• Mounting position of the gear unit• Operation conditions
The certified drawing shows the lubrication system that is used for your gear unit.
Splash lubricationSplash lubrication is the standard for gear units with horizontal LSS of these types:
Number of stages Speed at the HSS [min-1]
1 750 to 18002 750 to 18003 750 to 18004 1000 to 1800
In other conditions, the lubrication system can be different. The type plate shows theapproved speed of the HSS.
Force-feed lubricationAn oil pump lubricates all turning parts above the level of the oil bath. The oil pumppumps the oil through pressure lines.
There are different types of oil pumps:
• Integrated pump: one of the shafts of the gear unit operates the oil pump.• Motor pump: a motor operates the oil pump.
The lubrication can be circulation lubrication or pressure lubrication.
Integrated pump
Refer to the certified drawing for the lubrication system for your gear unit. The lubricationsystem can have these parts:
• A pump• A filter with bypass• A flow switch
The pump can operate in two directions of rotation.
Motor pump
A sign on the pump shows the direction of rotation of the motor shaft of the motor pump.
Breather plugA breather plug is installed to prevent a too high pressure in the gear unit.
Cooling systemA cooling system can be necessary to remove heat from the gear unit. Friction andchurning of gears and bearings in the gear oil causes the heat.
The certified drawing shows the cooling system that is used for your gear unit, if any.
4.4.2
4.4.3
4.5
4.6
Description
18 IM_405_002_EN
Direction of rotation of the shaftsAs a standard, the shafts of the gear unit can turn in two directions. If the shafts of thegear unit can only turn in one direction, a sign on the gear unit and the certified drawingshows this.
4.7
Description
IM_405_002_EN 19
Safety
RestrictionsWarning: Use of the gear unit in ways other than described in the relateddocuments may result in injury, death, or property and equipment damage.Use the gear unit only as described in the related documents.
H.I.T. cannot be held responsible for injuries or damages resulting from non-standard,unintended use of the gear unit. The gear unit is designed and intended only for thepurpose described in the related documents.
Unintended use includes these actions:
• Making changes to the gear unit that have not been recommended in the relateddocuments or using parts that are not replacement parts or accessories from H.I.T.
• Use of materials or equipment that are inappropriate or incompatible with the gearunit.
• Use of gear oils and grease that is not indicated on the type plate or the specificationsin this document.
• Allowing unapproved personnel to perform any task on or with the gear unit.
Approved installation engineerThe term approved installation engineer is specified here as a person that fully knows thegear unit and its safe operation. Approved installation engineers obey all related safetyregulations and are approved to safely install the gear unit.
It is the responsibility of the company that owns the system where the gear unit is part ofto make sure that all installation engineers obey these requirements.
General safety instructionsWarning: Obey the specifications that the certified drawing shows. Ifspecifications in this document and the certified drawing for the same item aredifferent, only the specifications in the certified drawing are applicable.
• When you do work on or with the gear unit, obey all legislation and regulations thatapply to safety and work requirements, that apply in the country and at the locationwhere you do work on the gear unit.
• Obey the safety instructions of the manufacturer of all chemical materials, includinggear oil and grease. Refer to the material data sheets of the chemical material. Makesure that all personnel that installs, does maintenance and servicing on the gear unit,receives these safety instructions.
• Do not open the gear unit near an open flame, spark or hot object. If not this cancause ignition of the fumes of the oil.
• If the gear unit is used as a part of a system that moves persons, obey all regulationsand install all necessary safety devices.
5
5.1
5.2
5.3
Safety
20 IM_405_002_EN
Safety instructions for installation• Make sure that the personnel that lift the gear unit are approved and obey state-of-the-
art safety procedures and state-of-the-art lifting equipment.• Obey the European Directives 2006/42/EG and the local safety regulations and install
guards and other safety equipment.• Make sure that the drive group the gear unit is a part of, cannot start when you install
the gear unit.• If safety devices are removed for installation, make sure they are correctly installed
again before you start the gear unit.• Make sure that the installation agrees with the EMC directive.
Special safety instructions (backstop)Warning:
• Do not loosen a part of the backstop when there is load on the gear unit. Inthis condition, the gear unit can turn in the incorrect direction.
• Make sure that a failure of a backstop cannot cause injury or damage tothe system.
Noise and vibrationsThe drive group, which the gear unit is a part of, and the attached parts cause vibrationsand noise.
To agree with local legislation, it can be necessary to decrease the noise of the drivegroup and the attached parts. Speak to H.I.T.
If you cannot do such procedures, all personnel that does work with or adjacent to thedrive group must wear correct personnel protection equipment, to decrease the noise tothe ears.
Make sure that the vibration agrees with ISO standard 10816-3.
Partly completed machineThe gear unit is a partly completed machine. It is a part of a drive group. Refer to thedocumentation of the drive group and obey all instructions of the drive group.
Instructions in case of a fireWarning: After a fire, protective clothing and respiratory equipment aremandatory to handle the gear unit. After a fire, the gear unit can containdangerous substances that cause injury when you touch or breath them.
• Do not start a gear unit that has burn marks. Speak to H.I.T.• Hazardous substances of combustion can be generated in a fire involving materials in
section Materials of the gear unit on page 52.
5.4
5.5
5.6
5.7
5.8
Safety
IM_405_002_EN 21
WarrantyThe warranty clause of the general conditions of sale applies to gear units installed andmaintained as per instructions contained in this document, including the relateddocuments, and in any additional instruction leaflets supplied with the gear unit insofar asthe gear unit operates within the service and rating conditions put forward in the orderacknowledgment and on the certified drawing.
Non compliance with these instructions, injudicious choice of lubricant or a lack ofmaintenance will render warranty agreement invalid.
This warranty clause applies to all parts of the gear unit with the exception of those partswhich are subject to wear.
5.9
Safety
22 IM_405_002_EN
Transport
Off-site transportCaution: Prevent vibration of the gear unit. Vibration can cause damage to thegears and the bearings.
Procedure
1. If you move the gear unit with a train, prevent damage to gears and bearings. Use ananti-brinelling device.
On-site transport
Lift the gear unitNote: The certified drawing shows more data:
• dimensions• mass
H.I.T. makes sure that all necessary lifting points are installed on the gearunit.
These are the possible lifting points:
A B C
A Integrated lifting eye
B Integrated bar
C Lifting eye and bolt
6
6.1
6.2
6.2.1
Transport
IM_405_002_EN 23
Prepare to lift the gear unit
Warning:
• Make sure that the personnel that lift the gear unit are approved and obeystate-of-the-art safety procedures and use state-of-the-art liftingequipment.
• Do not connect the lifting equipment to other parts of the gear unit than thelifting points.
• If only the gear unit is supplied, use the lifting points to lift the gear unit.• If the gear unit is supplied as a part of a drive group on a chassis, refer to
the certified drawing for the correct lifting points.• If the gear unit is supplied as a part of a drive group without chassis, only
use the lifting points on the gear unit.
Caution: If parts of the gear unit are removed to move the gear unit, makesure that water or contamination cannot come into the lubrication system orthe gear unit.
Procedure
1. Do a check on the lifting points forthese signs:
• Fatigue• Cracks• Deformation• Rupture• Corrosion
2. If you see one of these signs, donot lift the gear unit.
3. For a gear unit with lifting eye nutsand bolts, make sure that the liftingeye (A) and the bolt (C) arecorrectly installed on the housing ofthe gear unit (B).
4. Make sure that the lifting equipmentagrees with all local regulations.
Lift the gear unit
Warning: Make sure that the lifting cables do not cause damage to externalcomponents of the gear unit.
A
B
C
Transport
24 IM_405_002_EN
X
A B
Procedure
1. For gear units with horizontal LSS with integrated lifting eyes: make sure that themaximum angle (X) of the lifting cables (A) is 45° in the plane of the long side of thegear unit.
2. For all other gear units, make sure that all lifting cables (B) are vertical and parallel toeach other.
3. Connect the lifting equipment to the gear unit. Use all lifting points of the gear unit.4. Lift the gear unit. Use the safe lifting equipment.
Transport
IM_405_002_EN 25
Storage
General storage instructionsThe storage period starts when the gear unit leaves H.I.T.Procedure
1. Prevent vibration of the gear unit.2. Make sure that:
• The ambient conditions for storage are correct. Refer to section Ambientconditions for storage on page 53.
• The gear unit is installed, started and in operation before the end of the maximumstorage time.
3. If it is necessary to put the gear unit in storage for more than 1 year, speak to H.I.T.4. If a longer storage period, than shown in this chapter, is necessary, speak to H.I.T.
Indoor storage for maximum 1 yearProcedure
1. Obey also these instructions:
• Keep the gear unit in a dry area with a good airflow.• Make sure that weather conditions have no effect on the gear unit.
Extended storage outdoors for maximum 2 years (extendedoutdoor storage)The storage period starts when the gear unit leaves H.I.T.. For this date, refer to thedispatch form.Procedure
1. Make sure that the gear unit is installed, started and in operation before the end ofthe maximum storage time.
2. Obey also these instructions during the complete storage:a) Prevent vibration of the gear unit.b) Do not remove the gear unit from its seaworthy packing case.c) Make sure that the seaworthy packing case is above water level (no submersion
allowed).d) Put the seaworthy packing case on a stable and level ground.e) Put a plastic cover on the seaworthy packing case to prevent contamination with
dust and water.f) Make sure that there is no damage of the seaworthy packing case. If you see
damage to the seaworthy packing case, tell H.I.T. Services immediately.
7
7.1
7.2
7.3
Storage
26 IM_405_002_EN
Extended storage indoors for maximum 5 years (extendedindoor storage)The storage period starts when the gear unit leaves H.I.T.. For this date, refer to thedispatch document.Procedure
1. Make sure that the gear unit is installed, started and in operation before the end ofthe maximum storage time.
2. Obey these instructions during the complete storage:a) Prevent vibration of the gear unit.b) The ambient conditions for storage are correct. Refer to section Ambient
conditions for storage on page 53.c) Keep the gear unit in a dry area with a good airflow.d) Make sure that weather conditions have no effect on the gear unit.e) Put the gear unit on a stable and level ground.f) Put a plastic cover on the gear unit to prevent contamination with dust.
3. Each year, do these inspections on the gear unit:a) Examine the paint on the gear unit for damage.b) Examine all bare surfaces for damage.c) Apply anti-oxidising waxy varnish on all bare machined surfaces. Refer to
section Corrosion protection by H.I.T. on page 52.4. Each 2 years, fill the gear unit again with rust preventive mineral oil.
a) Drain the oil from the gear unit. Refer to section Drain gear oil on page 41.b) Add a volatile corrosion inhibitor to the gear oil. Speak to the supplier of the gear
oil for instructions. Do not add more volatile corrosion inhibitor than specified insection General specifications for lubricants on page 61.
c) Seal all openings of the gear unit.d) With your hand, turn the HSS until the LSS made 2 complete turns.
7.4
Storage
IM_405_002_EN 27
Installation
Maximum time between installation and commissioningProcedure
1. Make sure that the time between installation and commissioning is not more than 1month. If this is not possible, speak to H.I.T.
Remove the packaging materialProcedure
1. Move the package to a dry area that has a good airflow.2. Do a check for these items:
• Damage to the package.• Damage to the protection of machined surfaces and shaft extensions. For the
specification of the protection, refer to section Corrosion protection by H.I.T. onpage 52.
3. If you see damage, tell H.I.T. immediately.4. Remove the packaging material from the gear unit.5. Do a check if the gear unit agrees with the shipping papers.6. If the gear unit shows damage or does not agree with your order, tell H.I.T.
immediately.
Installation instructions for parts that are not part of the gearunitProcedure
1. For installation instructions of parts that are not included in this document: refer tothe drive package documentation.
2. For installation of electrical components: refer to section Related documents on page11.
Do a check for corrosion of internal parts of the gear unitProcedure
1. Open the inspection cover. For the location of the inspection cover, refer to thecertified drawing.
2. Do a check for corrosion of internal parts of the gear unit.3. If there is a sign of corrosion of internal parts of the gear unit, do these steps:
a) Make a report.b) Give the report to H.I.T.
Install the couplings
8
8.1
8.2
8.3
8.4
8.5
Installation
28 IM_405_002_EN
PrepareProcedure
1. Remove the grease and contamination from the shaft extensions and from thecoupling.
2. Make sure that the specifications of the coupling agree with the specifications on thecertified drawing.
Apply the sealing pasteProcedure
1. Apply a sealing paste to the contactsurfaces A, B, C and D. For thetype of the sealing paste, refer toyour supplier of the sealing paste.The sealing paste preventsmoisture, which can causecorrosion, to come between theparts.
Install the coupling hubsCaution: Make sure that the temperature of the shafts, during the installationof the coupling hubs, is lower than 100 °C .
Procedure
1. Install the spacer between the shaftshoulder and the coupling hub.
2. Install the coupling hubs on theshaft extensions. If necessary,apply heat on the couplings.
3. Make sure that the surface of theshaft extension (A) is flush with thesurface (B) of the coupling or thatthe distance (X) is as low aspossible (not negative). Obey thespecifications of the supplier of thecoupling.
4. If necessary, install more parts.Refer to the certified drawing:
• Thrust washer• Bolt
5. Make sure that the assembly of the coupling hub, the spacer, the thrust washer andthe bolt agree with these specifications. Speak to H.I.T. to get specifications.
A B C D
B
A
X
Installation
IM_405_002_EN 29
Remove unwanted sealing paste and apply paintProcedure
1. Remove the sealing paste from all surfaces that are not contact surfaces.2. Do a check for openings between the parts.3. If you see openings, apply sealing paste and do steps 1 and 2 again.4. Apply a protection on the oil seals of the gear unit to prevent them from
contamination.5. Apply paint on all parts. Make sure that the paint agrees with the correct atmospheric
corrosion class. Refer to the order acknowledgement.
Install parts that give external loads to the gear unitNote: Only do the steps if it is necessary to install parts that give externalloads on the gear unit.
Procedure
1. Make sure that the gear unit does not move during operation. Install thrust blocks.2. Make sure that the distance between the external load and the housing of the gear
unit is as small as possible.3. Make sure that only the external loads that agree with the order acknowledgement or
the certified drawing work on the gear unit. This includes the loads of the machine inoperation.
Install gear units with a backstopWarning:
• Do not loosen a part of the backstop when there is a load on the gear unit.In this condition, the gear unit can turn in the incorrect direction.
• Make sure that a failure of a backstop cannot cause injury or damage tothe system.
• If the gear unit is used as a part of a system that moves persons, obey allregulations and install all necessary safety devices.
Caution: Do not turn the gear unit in the incorrect direction. This conditioncauses damage to the backstop.
Procedure
1. Make sure that the direction of rotation of the backstop shaft agrees with the directionof rotation of the machine shaft.
Note: For drive groups, use a phase meter to do a check on the directionof rotation of the machine shaft.
2. If it is necessary to change the direction of the backstop shaft, speak to H.I.T.
8.6
8.7
Installation
30 IM_405_002_EN
Align the gear unit
Align the gear unit in the horizontal planeProcedure
1. Put the gear unit in the correct position, as shown in the certified drawing.For instructions on how to lift the gear unit, refer to section Transport on page 23.
2. If it is necessary to install the gear unit in a position that is different from the positionin the certified drawing, speak to H.I.T.
3. Put the gear unit on a rigid and stable bedplate or foundation.4. Use 3 bolt holes and align the gear unit. Only use the bolt holes that are shown in the
certified drawing.5. Make sure that the inclination is correct. Refer to section Position of the gear unit on
page 53.6. Adjust the vertical position at the other bolt holes. Use spacers.7. Make sure that the vertical adjustment of the other bolt holes agrees with the
specification. Refer to section Position of the gear unit on page 53.
Align the LSS (multi-stage)Caution: Obey the specifications. If not, the lifetime of the bearings and thecouplings will be decreased.
Procedure
1. Make sure that only the external loads that agree with the order acknowledgement orthe certified drawing work on the gear unit. This includes the loads of the machine inoperation.
2. Make sure that the combination of the angular and radial misalignment agrees withthe specfication in section Misalignment of the LSS on page 53.
Align the LSS (single stage)Procedure
1. Make sure that the misalignment is not more than specified. Refer to section Misalignment of the HSS (couplings) on page 53.
2. If you use a flexible gear coupling, speak to H.I.T. and give all external causes thathave an effect on the gear unit.
3. Wait until H.I.T. gives specifications for the misalignment.4. Make sure that the misalignment is not more than these specifications.
8.8
8.8.1
8.8.2
8.8.3
Installation
IM_405_002_EN 31
Align the HSSProcedure
1. Make sure that the misalignment is not more than specified. Refer to section Misalignment of the HSS (couplings) on page 53.
2. If you use a flexible gear coupling, speak to H.I.T. and give all external causes thathave an effect on the gear unit.
3. Wait until H.I.T. gives specifications for the misalignment.4. Make sure that the misalignment is not more than these specifications.
Attach the gear unit with the bolts (solid shafts)Warning: If safety devices are removed for installation, make sure that theyare correctly installed again before you start the gear unit.
Attach the gear unitProcedure
1. Install the applicable bolts at the bolt holes of the gear unit. For the dimension andquality of the bolts, refer to section Bolt specifications (gear units with solid shafts) onpage 54.
2. Tighten the bolts. For the correct torque, refer to section Bolt specifications (gearunits with solid shafts) on page 54.
3. Do a check on the position of the gear unit. Refer to section Align the gear unit onpage 31.
4. If the position does not agree with the specifications:a) Loosen the bolts.b) Align the gear unit. Refer to section Align the gear unit on page 31. Start with
step 2 until the position agrees with the specifications.
Install the safety coverProcedure
1. Install the safety cover.
Attach the gear unit (hollow shafts)
Install the shrink diskWarning:
• Do not disassemble the shrink disk. H.I.T. prepared it for installation.• Obey the specifications that the certified drawing shows. If specifications in
this document and the certified drawing for the same item are different, thespecifications in the certified drawing are applicable.
8.8.4
8.9
8.10
8.10.1
Installation
32 IM_405_002_EN
Lubricate the contact surfaceProcedure
1. Clean and remove grease from thecontact surfaces (A) and (B).
2. Apply lubricant, only to contactsurface (A). For the lubricantspecification, refer to section Lubrication on page 58.
3. Do not apply lubricant to thesurfaces (B). If there is lubricant onthese surfaces, the friction betweenthe machine shaft and the shaft ofthe gear unit will not be correct.
4. Wait until the lubricant is dry.
Attach the gear unit to the machine shaft
Caution: Make sure that there is no opening between the parts (A), (D) and(E). If there is an opening, water can come in and cause corrosion.
Note: The parts (F), (G) and (H) are not a part of the gear unit. Speak to H.I.T.if it is necessary that H.I.T. supplies these parts.
Procedure
1. Install the O-ring (A) on themachine shaft (B).
2. Move the gear unit (C) until thesurfaces (D) and (E) tightly toucheach other. Use the threaded rod(F), the nut (G) and the installationdisk (H).
Install the shrink disk
Caution:
• Obey the instructions of the supplier of the shrink disk. Refer to the drivepackage documenation.
• Do not tighten the bolts crosswise.• Do not tighten the bolts when the shrink disk is not at the correct location
on the shaft.
BB
BA
GH
D
E
CA B
F
Installation
IM_405_002_EN 33
Note: The instructions from this point in the procedure only apply to 2-partshrink disk of the types shown in section Shrink disk specifications (2-partshrink disk) on page 58.
Procedure
1. Install the shrink disk (A) to theposition marked with a locatinggroove (B).
2. Tighten 4 bolts (C), approximatelyequally spaced, 3/5 of the correcttorque. Refer to section Torquespecifications on page 59.
3. Tighten all screws in several stepsclockwise and increase the torquegradually to the correct torque.Make sure to keep inner ring andouter ring parallel during the wholetightening process.
4. Remove the threaded rod, the nutand the installation disk that areused for installation.
Instructions if the shoulder of the machine shaft does not absorb the axial loadProcedure
1. Install the locking disk (A) and thebolts (B).
2. Refer to the certified drawing formore instructions.
Install the safety coverProcedure
1. Install the safety cover.
Install the shaft with keyway connection
A
CB
Nm
B
A
8.10.2
Installation
34 IM_405_002_EN
Lubricate the contact surfaceProcedure
1. Clean and remove grease from thecontact surfaces (A) and (B).
2. Apply lubricant, only to contactsurfaces (A) and (B). For thelubricant specification, refer tosection Lubrication on page 58.
3. Wait until the lubricant is dry.
Install the installation key on the machine shaftProcedure
1. Install the O-ring (A) on themachine shaft (B).
2. Install the installation key (C) in thekeyseat (D) of the machine shaft.
3. Make sure that the short leg of theinstallation key touches the end ofthe machine shaft.
Install the gear unit on the machine shaft
Note: The parts (D), (E) and (F) are not a part of the gear unit. Speak to H.I.T.if it is necessary that H.I.T. supplies these parts.
BB
BA
CDBA
Installation
IM_405_002_EN 35
Procedure
1. Align the gear unit (A) with themachine shaft (B). Make sure thatthe keyways of the machine shaftand the hollow shaft align.
2. Move the gear unit until theinstallation key (C) and theinstallation disk (D) touch eachother. Use the threaded rod (E), thenut (F) and the installation disk.
3. Remove these parts:
• threaded rod• nut• installation disk• installation key
Do a check on the final keyProcedure
1. Measure the clearance between the final key and the keyway of the hollow shaft.2. Compare the clearance with the specification. Refer to the certified drawing.3. If the clearance is not correct, use a new final key.
Install the final key
Caution: Make sure that there is no opening between the parts (F), (G) and(H). If there is an opening, water can come in an cause corrosion.
Procedure
1. Install the final key (A) in thekeyway (B).
2. Install the installation disk (C), thenut (D) and the threaded rod (I).
3. Move the gear unit (E) until thesurfaces (F) and (G) firmly toucheach other. Use the threaded rod(I), the nut and the installation disk.
4. Remove the threaded rod, the nutand the installation disk that areused for installation.
B C
FD E
A
HF AB
DC I
EG
Installation
36 IM_405_002_EN
Install the locking diskProcedure
1. Install the locking disk (A) and thebolts (B).
2. Install the safety cover.
Install the safety coverProcedure
1. Install the safety cover.
Install the torque arm
Install the torque armProcedure
1. Attach the gear unit to a torque reaction point. Use a torque arm. Refer to thecertified drawing for the location of the torque arm on the gear unit.
Prestress the disk springs of the torque arm
This is necessary to make sure that the connection between the torque arm and thetorque reaction point stays flexible and resilient.
B
A
8.10.3
Installation
IM_405_002_EN 37
Procedure
1. Turn the nut (A) to decrease thedistance (X) with a distance (Y). (X)is the distance between the torquereation point (B) and the gear unit(C).
• This step prestresses the disksprings.
• For the specification of (Y), referto section Prestressspecifications for the torque arm(hollow shaft) on page 60.
Note: (Y) is thedifference between thedistance without loadand the distance whenthe disk springs areprestressed.
2. Turn the nut (D) tightly against the nut (A).3. Apply torque seal to the nuts. Refer to section Torque seal specification on page 52.
Install a ground connectionWarning: Do not use the gear unit as a part of a circuit to ground othermachines.
Caution: Install a ground connection. If not, electric current can cause damageto the gears and the bearings.
Procedure
1. Ground the gear unit.
Install the lubrication system
General instructions for the lubrication systemWarning: Obey the safety instructions of the manufacturer of all chemicalmaterials, also of gear oil and grease. Refer to the material data sheets of thechemical material. Make sure that all personnel that installs, doesmaintenance and servicing on the gear unit, receives these safetyinstructions.Caution: Make sure that during operation, the temperature of the gear oil issatisfactory. Refer to section General specifications for lubricants on page61.
D
A
B
C
Y
X
8.11
8.12
8.12.1
Installation
38 IM_405_002_EN
Note: For more information on and instructions for these parts of the gear unit,refer to the certified drawing and the service manual of the lubrication andcooling system:
• Lubrication system• Instrumentation• Settings
Instructions for force-feed lubrication (integrated pump)Note: During startup, it is necessary to delay the alarm signal.
Procedure
1. Adjust the flow switch to make sure that the motor that operates the gear unit stopswhen the oil flow is less than the alarm level.
Instructions for force-feed lubrication (pump with a motor)Caution: Make sure that the motor of the pump turns in the correct direction. Ifnot, the gear unit is not lubricated correctly. This condition causes damage tothe gear unit.
Procedure
1. Refer to the service manual of the lubrication and cooling system.
Instructions for force-feed lubrication (pressure lubrication)Procedure
1. Refer to the service manual of the lubrication and cooling system.
Fill the gear unit with gear oil
Select the gear oilCaution:
• Only use the gear oil that agrees with the type plate and with section Lubricants on page 61. Do not use another type of gear oil.
• Only use the markings on the dipstick to measure the gear oil level.• Make sure that all items that can cause draining of the gear oil by accident
are secured
Note:
• H.I.T. is not responsible or liable if the supplier of oil changes thecomposition of the gear oil.
• It can be necessary to rinse the gear unit. Speak to the supplier of the gearoil.
8.12.2
8.12.3
8.12.4
8.13
8.13.1
Installation
IM_405_002_EN 39
Procedure
1. For the correct type and viscosity of gear oil, refer to the type plate.2. With the type and viscosity, select the gear oil from the tables in section Lubricants
on page 61.3. If the gear unit contains gear oil for storage, drain it.
Add gear oil (gear unit with motor base)Only do the procedure the first time you install the gear unit.
Add oil at the top side of the gear unit.
Procedure
1. Open the gear unit at the oil fill plug at the top side of the gear unit. Refer to the signon the gear unit and the certified drawing.
2. If you do not have access to the oil fill plug:a) Remove the belt.b) Lift the motor base.
3. Add 3 L of gear oil. If the certified drawing shows another quantity, add the quantityon the certified drawing. You can use an oil pump.
4. Lower the motor base.5. Install the belt.
Add gear oil (QHR.4, QVR.3 and QVR.4)Only do the procedure the first time you install the gear unit.
Add oil to the bearing housing.
Procedure
1. Open the gear unit at the oil fill plug for the bearing housing. Refer to the sign on thegear unit and the certified drawing.
2. Add 3 L of gear oil. If the certified drawing shows another quantity, add the quantityon the certified drawing. You can use an oil pump.
Measure the gear oil levelProcedure
1. Remove the dipstick (A). Refer tothe sign on the gear unit.
2. Clean the dipstick.3. Lower the dipstick fully.4. Remove the dipstick.5. Read the gear oil level on the
dipstick.6. If the gear oil level is below the
minimum level indicated on thedipstick, add gear oil.
7. If the gear oil level is above themaximum level indicated on thedipstick, drain gear oil.
8.13.2
8.13.3
8.13.4
A
Installation
40 IM_405_002_EN
Add gear oil (all gear units)Only do the procedure if it is necessary to add gear oil.
Caution: Before you use a different type of gear oil that is in the gear unit,speak to the supplier of the gear oil. Not all gear oils are compatible with eachother. The supplier of the gear oil gives instructions. Obey these instructions.
Procedure
1. Open the gear unit at the oil fill plug. Refer to the sign on the gear unit.2. Add gear oil.3. If the gear unit has a motor pump, make sure that the pump goes on for minimum 3
minutes.4. Measure the level of gear oil.
Drain gear oilOnly do the procedure if it is necessary to drain gear oil.
Procedure
1. Put a container below the oil drain. Refer to the sign on the gear unit.2. Open the gear unit at the oil drain. Gear oil comes out of the opening at the oil drain.3. If the gear unit has a magnetic plug, clean it.4. Close the oil drain. For the correct torque, refer to Torque values for oil drain screw
on page 58.5. Discard the gear oil in the container. Obey the local regulations to prevent
environmental pollution.6. Measure the gear oil level.
Add grease to the lubrication points for grease
Select the grease typeCaution: Only use the grease type that agrees with the type plate and withsection Lubricants on page 61. Do not use another grease type.
Note: If the supplier of grease changes the composition of the grease, H.I.T. isnot responsible or liable.
Procedure
1. For the correct grease type, refer to the type plate.2. Use this data to select the grease from the tables in section Lubricants on page 61.
Add greaseCaution: Before you use a different type of grease that is in the gear unit,speak to the supplier of the grease. Not all greases are compatible with eachother. The supplier of the grease gives instructions. Obey these instructions.
8.13.5
8.13.6
8.14
8.14.1
8.14.2
Installation
IM_405_002_EN 41
Note:
• The grease nipples agree with the standard DIN 71412 or optional DIN3404.
• For the grease quantity, refer to chapter Technical data on page 52.
Procedure
1. Add grease to the grease nipples. Refer to the signs on the gear unit. Use a greasegun.
Install the oil-to-air coolerProcedure
1. Obey the instructions for the cooling system. Refer to the service manual of thelubrication and cooling system.
Install the water cooling
Install the water coolingNote: If the certified drawing does not show the cooling water temperature,the water flow on the certified drawing is applicable to water at 20 °C (70 °F).
Procedure
1. Obey the instructions for the water cooling system. Refer to the service manual of thelubrication and cooling system.
Install the oil-to-water coolerCaution: Make sure that the quality of the cooling water agrees with thespecification in the service manual of the lubrication and cooling system.
Procedure
1. Connect the oil-to-water cooler to the cooling water supply.
8.15
8.16
8.16.1
8.16.2
Installation
42 IM_405_002_EN
Install the cooling coilsProcedure
1. Connect the cooling coil to thecooling water supply.
2. Make sure that the quality andwater pressure of the cooling wateragrees with the specifications.Refer to section Cooling waterspecifications on page 70.
3. While you connect the cooling coil(A), hold the connection (B) with anopen spanner (C), to preventtorsion on the cooling coil.
Installation instructions (heater)Procedure
1. Make sure that the heater automatically goes off if the temperature of the gear oil hasthe correct temperature. For the specification, refer to Additional gear oilspecifications (heater) on page 61.
8.16.3
A
B
C
8.17
Installation
IM_405_002_EN 43
Commissioning
Maximum time between commissioning and operationProcedure
1. Make sure that the time between commissioning and operation is not more than 2weeks. If this is not possible, speak to H.I.T.
Do a check on the gear unitProcedure
1. Do a check on the gear oil level. Refer to Measure the gear oil level on page 40.2. Make sure that all lubrication points for grease are filled.3. Make sure that all safety covers are installed correctly.
Start instructions (backstop)Caution: Do not turn the gear unit in the incorrect direction. This conditioncauses damage to the backstop.
Procedure
1. Make sure that the backstop operates correctly.
Start instructions (heater)Procedure
1. Do not start the gear unit if the temperature of the gear oil is not correct. For thespecification, refer to section Additional gear oil specifications (heater) on page 61.
Start instructions (force-feed lubrication, pump with a motor)Procedure
1. Make sure that the pump goes on minimum 60 s before the gear unit starts.2. For more instructions, refer to the service manual of the lubrication and cooling
system.
9
9.1
9.2
9.3
9.4
9.5
Commissioning
44 IM_405_002_EN
Start instructions (force-feed lubrication, integrated pump)Procedure
1. Delay the alarm signal, to stop the motor that operates the gear unit when the oil flowis low, with 5 s. If not, unwanted alarms occur during startup.
2. For more instructions, refer to the service manual of the lubrication and coolingsystem.
Start instructions (drive group with a 2-speed motor)Procedure
1. Before you change from the higher to the lower speed, decrease the speed belowthe lower speed.Then, the motor must increase the speed to the lower speed. This condition preventsthat the torque to the gear unit becomes too high.
Instructions after commissioningWarning: Do not disassemble an "OIL-LOCKTM" or the "OIL-GUARDTM"system on the HSS. If you see leaks at this location, speak to H.I.T.
Procedure
1. Do a check on the gear oil level. Refer to section Measure the gear oil level on page40.
2. While the gear unit operates, listen for unexpected noise and vibrations.3. If you hear unexpected noise and vibrations, remove the source of the unexpected
noise and vibrations.
Warning: Do not remove the safety covers.
4. Examine the surface of the gear unit and the adjacent parts.5. If you see leakage: find and remove the cause of the leakage.6. Clean all parts that have gear oil or grease on the surface.7. Make sure that the gear unit operates until the temperature is constant (ΔT < 1 °C / 1
h)8. Make sure that the gear unit is aligned correctly. Refer to section Align the gear unit
on page 31.
Warning: Do not touch the gear unit. It is hot. Use protective clothing
9.6
9.7
9.8
Commissioning
IM_405_002_EN 45
Instructions for operation
General instructions for operationCaution: If the instructions are not obeyed during operation, this causesdamage to the gear unit.
Procedure
1. Give all the instructions in this chapter to the owner of the gear unit.These instructions are a part of the instructions of a larger system in which the gearunit is one part.
Instructions (force-feed lubrication, pump with a motor)Procedure
1. Make sure that a pump goes on minimum 60 s before the gear unit starts.
Instructions (water cooling)Procedure
1. Drain the cooling water if the gear unit does not operate and the ambienttemperature is below the freezing point.
Instructions (drive group with a 2-speed motor)Procedure
1. Before you change from the higher to the lower speed, decrease the speed belowthe lower speed.Then, the motor must increase the speed to the lower speed. This condition preventsthat the torque to the gear unit becomes too high.
Instructions if the gear unit does not operate more than 2 weeksProcedure
1. Do one of these procedures:
• Operate the gear unit for minimum 5 minutes each 2 weeks.• Protect the gear unit with a volatile corrosion inhibitor.
2. Before you start again, do all instructions in chapter Commissioning on page 44.
10
10.1
10.2
10.3
10.4
10.5
Instructions for operation
46 IM_405_002_EN
Operate the gear unit for 5 minutes each 2 weeksProcedure
1. Operate the gear unit for minimum 5 minutes each 2 weeks. In this condition, thegear oil prevents corrosion of the internal parts of the gear unit.
Protect the gear unit with a volatile corrosion inhibitorProcedure
1. Add a volatile corrosion inhibitor to the gear oil. Speak to the supplier of the gear oilfor instructions. Do not add more volatile corrosion inhibitor than specified in section General specifications for lubricants on page 61.
2. Seal all openings of the gear unit.
Instructions for operation
IM_405_002_EN 47
Removal of the gear unit
General instructions for removal of the gear unitWarning:
• Obey the instructions on how to move the gear unit when it is on-site.Refer to section On-site transport on page 23.
• Make sure that the gear unit cannot fall. Make sure that safe liftingequipment holds the gear unit.
Procedure
1. For removal instructions of parts that are not included in this document: refer to thedrive package documentation.
2. Make sure that there is no load or torque on the gear unit.
Remove the gear unit (solid shafts, couplings)Procedure
1. Disconnect the coupling. If H.I.T. supplied the coupling, refer to the certified drawing.If H.I.T. did not supply the coupling, refer to the instructions of the coupling.
2. Remove the bolts that connect the gear unit to the bedplate or foundation. Refer tothe certified drawing.
3. To move the gear unit, refer to section On-site transport on page 23.
Remove the gear unit (hollow shafts)
Disconnect the gear unit from the torque reaction pointProcedure
1. Remove the nuts (A) and (B).
Remove the shrink disk
11
11.1
11.2
11.3
11.3.1
A
B
11.3.2
Removal of the gear unit
48 IM_405_002_EN
Remove the shrink diskProcedure
1. Remove the safety cover.2. Loosen the bolts (A) 1/4 of a turn.
Start with one bolt and continuecounterclockwise until the last bolt.
3. Do the step 1 again until all boltsare loose. Do not remove the bolts.
4. If the shrink disk does not becomeloose, install bolts in the holes (B)and tighten them. This way, theinner ring (D) and the outer ring (C)are pushed away from each other.
5. Remove the shrink disk.6. If the shrink disk is dirty:
• Clean the shrink disk.• Apply a solid lubricant to the
machined surfaces. Refer to section Lubrication on page 58.
Remove the gear unitProcedure
1. Install these parts:
• Installation disk (A)• Bolts (B) (for the type of bolts,
refer to the certified drawing)• Bolt to remove the gear unit (C)
2. To remove the gear unit from themachine shaft, tighten the bolt (C).
3. To move the gear unit, refer tosection On-site transport on page23.
Disconnect the keyway connection
C
A
D
B
Nm
B
A
C
11.3.3
Removal of the gear unit
IM_405_002_EN 49
Remove the locking diskProcedure
1. Remove the safety cover.2. Remove the bolts (B).3. Remove the locking disk (A).
Remove the gear unitProcedure
1. Install these parts:
• Installation disk (A)• Bolts (B) (for the type of bolts,
refer to the certified drawing)• Bolt to remove the gear unit (C)
2. To remove the gear unit from themachine shaft, tighten the bolt (C).
3. To move the gear unit, refer tosection On-site transport on page23.
B
A
B
A
C
Removal of the gear unit
50 IM_405_002_EN
Care for the environmentMake sure to dispose the gearbox and its components in accordance with localregulations at the end of their service life.
The best disposal is to avoid the creation of waste by recycling.
• Always observe environmental regulations when disposing used oil.Do not dump it on garden soil, wooded areas, into open streams ordown sewage drains. Make sure to remove any spillage at once.
• Sort metal components correctly and offer for recycling.• Sort electrical components correctly and offer for recycling.• Materials not suited for recycling must be disposed of in accordance
with regulations.
12
Care for the environment
IM_405_002_EN 51
Technical data
Dimensions and massRefer to the certified drawing.
Materials of the gear unit• Gear oil• Grease• FKM (a type of fluoroelastomer)• Copper• Aluminium• Polycarbonate (solid)• Polypropylene (with embedded glass fibre or with carbon)• Polyamide (solid)• Polyphenol sulfide (solid)• For information on the paint and other materials, refer to the drive package
documentation.
Torque seal specificationParameter Specification
Torque seal Loctite 7417 torque Marque or similar
Paint specificationParameter Specification
Primer Two-component, polyamide-cured epoxy pre-fabrication primer (20µm)
Finish Two-component, high build, polyamine adduct-cured epoxy coating (200µm)
Total average minimum dry film thickness 220µm
Corrosion protection by H.I.T.Parameter Specification
Inner parts Rust preventive mineral oilBreather plug Present but not sealedShaft extensions Rust preventive greaseHollow shafts Anti-oxidising waxy varnishUnpainted machined surfaces Anti-oxidising waxy varnish
13
13.1
13.2
13.3
13.4
13.5
Technical data
52 IM_405_002_EN
Position of the gear unitParameter Specification
Inclination Maximum 5 mm per 1 m (5/32 inch per 3 feet or5 mrad or 17 arc minutes)
Accuracy of the vertical position from the fourthconnection point [mm] ([inch])
0.1 (0.004)
Ambient conditions for storageParameter Specification
Temperature [°C] Above dew point temperatureRelative humidity, non-condensing [%] Maximum 60General protection Against corrosion and contaminationVibration Not allowed
Misalignment of the LSSParameter Specification
dr
∆r
dα
∆α+
Misalignment equation, where
• dr = measured radial misalignment [mm]• Δr = maximum permitted radial misalignment
[mm]• dα = measured angular misalignment [mm]• Δα = maximum permitted angular misalign-
ment [mm]
Smaller than or equal to 1
Misalignment of the HSS (couplings)Type of coupling Speed of the HSS [1/min ] Maximum permitted misalign-
ment [mm] ([mils])
Short flexible coupling, radialmisalignment
750 0.19 (7.5)900 0.15 (6.0)1000 0.12 (4.8)1200 0.10 (4.0)1500 0.09 (3.5)1800 0.08 (3.0)
Angular misalignment for cou-pling diameter 100 mm (10inch)
750 0.13 (13.0)900 0.10 (10.0)10000 0.096 (9.6)1200 0.08 (8.0)1500 0.07 (7.0)1800 0.05 (5.0)
13.6
13.7
13.8
13.9
Technical data
IM_405_002_EN 53
Type of coupling Speed of the HSS [1/min ] Maximum permitted misalign-ment [mm] ([mils])
Radial misalignment for thespacer shaft and membrane(disk) coupling, spacer length100 mm (1 inch)
750 0.25 (2.5)900 0.20 (2.0)1000 0.18 (1.8)1200 0.15 (1.5)1500 0.12 (1.2)1800 0.10 (1.0)
Bolt specifications (gear units with solid shafts)
Bolt specifications (single-stage, horizontal LSS)
Table for bolts according to DIN 267 bolt quality grade 8.8
Gear unit type Gear unit size Bolt dimension [ISO] Torque [Nm]
QHP.1 C M20 335
D M24 675
E M24 675
F M30 1350
G M30 1350
QHP.1T G M36 2350
H M36 2350
J M36 2350
K M36 2350
Table for bolts according to SAE bolt quality grade 5
Gear unit type Gear unit size Bolt dimension [UNC] Torque [lbf.in]
QHP.1 C 3/4" 2950
D 7/8" 4850
E 1" 6000
F 1 1/8" 10300
G 1 1/4" 12000
QHP.1T G 1 1/2" 21000
H 1 1/2" 21000
J 1 1/2" 21000
K 1 1/2" 21000
13.10
13.10.1
Technical data
54 IM_405_002_EN
Bolt specifications (multi-stage, horizontal LSS)
Table for bolts according to DIN 267 bolt quality grade 8.8
Gear unit type Gear unit size Bolt dimension [ISO] Torque [Nm]
QH... A M16 180
B M20 335
C M24 675
D M24 675
E M30 1350
F M30 1350
G M36 2350
H M36 2350
J M36 2350
K M36 2350
L M42 3800
M M42 3800
N M48 5700
P M48 5700
Q M48 5700
R M56 9150
S M56 9150
T M56 9150
13.10.2
Technical data
IM_405_002_EN 55
Table for bolts according to SAE bolt quality grade 5
Gear unit type Gear unit size Bolt dimension [UNC] Torque [lbf.in]
QH... A 5/8" 1550
B 3/4" 2950
C 7/8" 4850
D 1" 6000
E 1 1/4" 12000
F 1 1/4" 12000
G 1 1/2" 21000
H 1 1/2" 21000
J 1 1/2" 21000
K 1 1/2" 21000
L 1 3/4" 33650
M 1 3/4" 33650
N 2" 50750
P 2" 50750
Q 2" 50750
R 2 1/4" 81050
S 2 1/4" 81050
T 2 1/4" 81050
Technical data
56 IM_405_002_EN
Bolt specifications (multi-stage, vertical LSS)
Table for bolts according to DIN 267 bolt quality grade 8.8
Gear unit type Gear unit size Bolt dimension [ISO] Torque [Nm]
QV... A M16 180
B M20 335
C M24 675
D M30 1350
E M30 1350
F M36 2350
G, 2-stage M36 2350
G, 3-stage and 4-stage M42 3800
H M42 3800
J M42 3800
K M42 3800
L M48 5700
M M48 5700
N M48 5700
P M48 5700
Q M48 5700
R M56 9150
S M56 9150
T M56 9150
13.10.3
Technical data
IM_405_002_EN 57
Table for bolts according to SAE bolt quality grade 5
Gear unit type Gear unit size Bolt dimension [UNC] Torque [lbf.in]
QV A 5/8" 1550
B 3/4" 2950
C 1" 6000
D 1 1/8" 10300
E 1 1/4" 12000
F 1 1/2" 21000
G, 2-stage 1 1/2" 21000
G, 3-stage and 4-stage 1 3/4" 33650
H 1 3/4" 33650
J 1 3/4" 33650
K 1 3/4" 33650
L 2" 50750
M 2" 50750
N 2" 50750
P 2" 50750
Q 2" 50750
R 2 1/4" 81050
S 2 1/4" 81050
T 2 1/4" 81050
Torque values for oil drain screwDimension of the drain screw Torque
G ½ " 56,5 Nm
G ¾ " 73,4 Nm
≥ G 1 " 79 Nm
Shrink disk specifications (2-part shrink disk)
Lubrication
Parameter Specification
Lubricant Molykote D321R or similar (friction coefficient:0.04)
13.11
13.12
13.12.1
Technical data
58 IM_405_002_EN
Torque specifications
A
C
B
Gear unit size H.I.T.part number of the shrinkdisk
Torque of the bolts (A), for the2-part shrink disk [Nm]3
A 901-SDA2D110001 120
B 901-SDA2D125001 120
C 901-SDA2D140001 190
D 901-SDA2D165001 290
E 901-SDA2D185001 290
F 901-SDA2D220001 570
G 901-SDA2D240001 570
H 901-SDA2D260001 570
J 901-SDA2D280001 570
K 901-SDA2D320001 990
L 901-SDA2D340001 990
M 901-SDA2D360001 990
N 901-SDA2D390001 1480
P 901-SDA2D420001 1480
Q 901-SDA2D440001 1480
R 901-SDA2D480001 1980
S 901-SDA2D500001 1980
T 901-SDA2D530001 1980
13.12.2
3 Torque values only valid for 'Sumitomo Drive Technologies' branded shrink disc. For other brands,obey the mounting instructions and torque values of the manufacturer.
Technical data
IM_405_002_EN 59
Prestress specifications for the torque arm (hollow shaft)
Y
Note: (Y) is the difference between distance without load and the distancewhen the disk springs are prestressed.
Gear unit type Y
[mm] [inch]
QH.A2 0.7 0.028
QH.B2 0.7 0.0.28
QH.C2 0.9 0.035
QH.D2 0.9 0.035
QH.E2 1.0 0.039
QH.F2 1.0 0.039
QH.G2 1.0 0.039
QH.H2 1.0 0.039
QH.C3 0.7 0.028
QH.D3 0.9 0.035
QH.D4 0.9 0.035
QH.E3 0.9 0.035
QH.E4 0.9 0.035
QH.F3 1.0 0.039
QH.F4 1.0 0.039
QH.G3 1.0 0.039
QH.G4 1.0 0.039
QH.H3 1.0 0.039
QH.H4 1.0 0.039
QH.J3 1.4 0.055
QH.J4 1.4 0.055
13.13
Technical data
60 IM_405_002_EN
Gear unit type Y
[mm] [inch]
QH.K3 1.4 0.055
QH.K4 1.4 0.055
QH.L3 1.4 0.055
QH.L4 1.4 0.055
QH.M3 1.4 0.055
QH.M4 1.4 0.055
Lubricants
General specifications for lubricants
Parameter Specification
Initial gear oil cleanliness -/15/12 (or better) according to ISO 4406
Gear oil: maximum allowable water content(Karl Fischer) [%]
0,05
NLGI-Grade of grease 3
2 or 3, for labyrinth seals and lower bearing ofthe LSS
Nominal temperature of the gear oil in the oilbath, during operation [°C] ([°F])
60 - 80 (140 - 180)
Maximum volume concentration of corrosion in-hibitor in the gear oil [%]
2
Working temperature range for corrosion inhibi-tor [°C] ([°F])4
15 - 70 (60 - 158)
General specifications for gear oil per viscosity grade
Viscosity grade AGMA SUS/100°F
ISO VG150 4 690
ISO VG220 5 1100
ISO VG320 6 1600
ISO VG460 7 2300
Additional gear oil specifications (heater)Parameter Specification
Minimum gear oil temperature for startup Refer to the type plateGear oil temperature at which the heater muststop [°C] ([°F])
15 (60), unless the certified drawing shows an-other specification. Then, refer to the certifieddrawing.
13.14
13.14.1
13.14.2
4 Make sure to store the gearbox in this temperature range for at least 5 days after each fill of corrosioninhibitor. Afterwards the conditions for storage apply. Refer to Ambient conditions for storage on page53
Technical data
IM_405_002_EN 61
Mineral gear oil and related grease
Table 1: Mineral gear oil
Supplier ISO VG150 ISO VG220 ISO VG320 ISO VG460
ADDINOL Eco Gear 150 M Eco Gear 220 M Eco Gear 320 M Eco Gear 460 M
BP-CASTROL Alpha SP 150 Alpha SP 220 Alpha SP 320 Alpha SP 460
FUCHS Renolin CLP 150 Renolin CLP 220 Renolin CLP 320 Renolin CLP 460
KLÜBER Klüberoil GEM1-150 N
Klüberoil GEM1-220 N
Klüberoil GEM1-320 N
Klüberoil GEM1-460 N
LUBRICATIONENGINEERS INC.
Duolec Vari-Pur-pose Gear Lubri-cant 1605
Duolec Vari-Pur-pose Gear Lubri-cant 1606
Duolec Vari-Pur-pose Gear Lubri-cant 1607
EXXON MOBIL Mobilgear XMP150
Mobilgear XMP220
Mobilgear XMP320
Mobilgear XMP460
Mobilgear 600 XP150
Mobilgear 600 XP220
Mobilgear 600 XP320
Mobilgear 600 XP460
REPSOL Super Tauro FND220
Super Tauro FND320
SHELL Omala F 150 Omala F 220 Omala F 320 Omala F 460
SHELL Omala S2 GX 150 Omala S2 GX 220 Omala S2 GX 320 Omala S2 GX 460
SINOPEC SINOPEC APGear Oil 220
SINOPEC APGear Oil 320
SINOPEC APGear Oil 460
STATOIL LoadWay EP 150 LoadWay EP 220 LoadWay EP 320 LoadWay EP 460
TOTAL Carter XEP 220 Carter XEP 320 Carter XEP 460
Carter EP 220 Carter EP 320 Carter EP 460
Table 2: Related grease
Supplier Related grease, NLGI grade 2 Related grease, NLGI grade 3
BP-CASTROL Spheerol EPL-2 Spheerol EPL-3FUCHS EUROPE SCHMIER-STOFFE
Renolit FEP 2 Renolit FEP 3
KLÜBER Centoplex 2EP -(EXXON)MOBIL - Mobilux EP 3SHELL Gadus S2 V220 2 Gadus S2 V220 3STATOIL Uniway Li 62 -TOTAL - Multis EP 3ADDINOL Multi-grade grease LM 2 EP Multi-grade grease LM 3 EP
13.14.3
Technical data
62 IM_405_002_EN
Synthetic gear oil and related greaseThe synthetic oil must be of the poly-alpha-olefin type (SHF-type, Synthetic HydrocarbonFluid).
Table 3: Gear oil
Supplier ISO VG150 ISO VG220 ISO VG320 ISO VG460
ADDINOL Eco Gear 150 S Eco Gear 220 S Eco Gear 320 S Eco Gear 460 S
Eco Gear 150 W Eco Gear 220 W Eco Gear 320 W Eco Gear 460 W
ANDEROL ANDEROL 5220Plus
ANDEROL 5320Plus
ANDEROL 5460Plus
ANDEROL 5150XEP
ANDEROL 5220XEP
ANDEROL 5320XEP
ANDEROL 5460XEP
BEL-RAY Synthetic Gear Oil150
Synthetic Gear Oil220
Synthetic Gear Oil320
Synthetic Gear Oil460
BP Enersyn EP-XF150
Enersyn EP-XF220
Enersyn EP-XF320
Enersyn EP-XF460
CASTROL Alphasyn EP 150 Alphasyn EP 220 Alphasyn EP 320 Alphasyn EP 460
ENGEN Gengear SPLA-220
Gengear SPLA-320
Gengear SPLA-460
EXXON MOBIL Mobilgear SHCXMP 150
Mobilgear SHCXMP 220
Mobilgear SHCXMP 320
Mobilgear SHCXMP 460
Mobil SHC GearSeries 150
Mobil SHC GearSeries 220
Mobil SHC GearSeries 320
Mobil SHC GearSeries 460
Mobil SHC 630 Mobil SHC 632 Mobil SHC 634
FUCHS Renolin UnisynCLP 150
Renolin UnisynCLP 220
Renolin UnisynCLP 320
Renolin UnisynCLP 460
INDIAN OILCOMPANY LIMI-TED
SERVOSYN-MESH GOLD 150
SERVOSYN-MESH GOLD 220
SERVOSYN-MESH GOLD 320
SERVOSYN-MESH GOLD 460
KLÜBER Klübersynth GEM4-150 N
Klübersynth GEM4-220 N
Klübersynth GEM4-320 N
Klübersynth GEM4-460 N
LUBRICATIONENGINEERS INC.
Duolec Syn GearLubricant 9822
Duolec Syn GearLubricant 9832
Duolec Syn GearLubricant 9846
PETRO-CANADA ENDURATEXSynthetic EP 220
ENDURATEXSynthetic EP 320
ENDURATEXSynthetic EP 460
Q8 Oils Q8 Galilei 150 Q8 Galilei 220 Q8 Galilei 320 Q8 Galilei 460
REPSOL SUPER TAUROSINTETICO 220
SUPER TAUROSINTETICO 320
SUPER TAUROSINTETICO 460
13.14.4
Technical data
IM_405_002_EN 63
Supplier ISO VG150 ISO VG220 ISO VG320 ISO VG460
SHELL Omala S4 GX 150 Omala S4 GX 220 Omala S4 GX 320 Omala S4 GX 460
SHELL Omala S4 GXV150
Omala S4 GXV220
Omala S4 GXV320
Omala S4 GXV460
SINOPEC SINOPEC AP-SGear Oil 150
SINOPEC AP-SGear Oil 220
SINOPEC AP-SGear Oil 320
SINOPEC AP-SGear Oil 460
TOTAL Carter SH 220 Carter SH 320 Carter SH 460
Table 4: Related grease
Note: For all synthetic gear oils, you can only use the grease type in the table below.
Supplier Related grease, NLGI grade 2 Related grease, NLGI grade 3
FAG - Arcanol VIB3
Grease quantity at lubrication points for bearings
Grease quantity typeFor the grease quantity type: refer to the type plate.
The grease quantities only apply to the lubrication points that are indicated on the gearunit with the sign for lubrication point for grease at bearings.
13.15
13.15.1
Technical data
64 IM_405_002_EN
Grease quantity types Q1, Q2, Q3, Q6, Q7 and Q8
A
A Lubrication point
Gear unitsize
Grease quantity type
Q1 [g] Q2 [g] Q3 [g] Q6 [g] Q7 [g] Q8 [g]
C 50 60 50 100
D 60 80 60 130 100 120
E 90 110 90 180 130 170
F 120 150 120 240 180 220
G 170 200 170 220 320
H 180 230 180 280 400
J 220 280 220 320 410
K 260 320 260 320 500
L 320 400 320 410 590
M 340 410 340 370 700
N 380 380 290
P 470 470 350
Q 490 490 360
R 500 500 380
S 600 600 440
T 620 620 470
13.15.2
Technical data
IM_405_002_EN 65
Grease quantity type Q4
A B
A Lubrication point
B Lubrication point
Gear unit size Lubrication point
A [g] B [g]
Z 10 20
A 20 20
B 30 30
Grease quantity type Q5
A
B
A Lubrication point
B Lubrication point
Gear unit size Lubrication point
A [g] B [g]
Z 10 20
13.15.3
13.15.4
Technical data
66 IM_405_002_EN
Gear unit size Lubrication point
A [g] B [g]
A 20 20
B 30 30
Grease quantity type Q9
B C D
A
E
A
B - C -
D - E
30°- 45°X
X
X-X
A Lubrication point at the lower side
B Lubrication point at the upper side
C Lubrication point at the upper side
D Lubrication point at the upper side
E Lubrication point at the upper side
Gear unit size Lubrication point
A [g] B [g] C [g] D [g] E [g]
C 50 30 20 10
D 60 40 30 20
E 90 50 40 20
F 120 80 50 30
H 180
J 220
K 260
L 320
M 340
N 290
P 350
Q 360
13.15.5
Technical data
IM_405_002_EN 67
Grease quantity for lubrication points at labyrinth seals (LSS)
Grease quantity type
The grease quantities only apply to the lubrication points that are indicated on the gearunit with the sign for lubrication point for grease at labyrinth seals.
Grease quantity (single-stage)Gear unit type Grease quantity [g]
QHRC1Z-..N 75QHRD1Z-..N 75QHRF1Z-..N 45QHPC1 10QHPD1 10QHPE1 15QHPF1 25QHPG1 35QVPZ1 10QVPB1 10
Grease quantity (multi-stage)Gear unit type Grease quanitty [g]
Gear unit size LSS type
QVRZ2 50QVRZ2L 30QVRA2 70QVRA2L 40QVRB2 50QVRB2L 55A Solid 15
Hollow 10B Solid 22
Hollow 16C Solid 25
Hollow 25D Solid 35
Hollow 25
13.16
13.16.1
13.16.2
13.16.3
Technical data
68 IM_405_002_EN
Gear unit type Grease quanitty [g]
Gear unit size LSS type
E Solid 55Hollow 30
F Solid 60Hollow 65
G Solid 75Hollow 65
H Solid 60Hollow 120
J Solid 60Hollow 130
K Solid 130Hollow 145
L Solid 135Hollow 155
M Solid 145Hollow 160
N Solid 215P Solid 230Q Solid 240R Solid 255
Grease quantity for lubrication points at labyrinth seals (HSS)
Grease quantity type
The grease quantities only apply to the lubrication points that are indicated on the gearunit with the sign for lubrication point for grease at labyrinth seals.
Grease quantity (single-stage)Gear unit type Grease quantity [g]
QHPC1 10QHPD1 10QHPE1 20QHPF1 30QHPG1 40
13.17
13.17.1
13.17.2
Technical data
IM_405_002_EN 69
Grease quantity (multi-stage)Gear unit type Grease quantity [g]
Z 10A to H 10J to T 20
Cooling water specificationsParameter Specification
[MPa] [bar] [psi]
Maximum water pres-sure on the coolingcoils
0.8 8 116
Quality Fresh water or salt water
13.17.3
13.18
Technical data
70 IM_405_002_EN
Technical data
IM_405_002_EN 71
Headquarters ManufacturingEUROPE
Hansen Industrial Transmissions NVLeonardo Da Vincilaan 1 B-2650 Edegem | Antwerp | BelgiumPhone: +32 3 45012-11 | Fax: +32 3 [email protected]
Sumitomo (SHI) Cyclo Drive Germany GmbHCycloStraße 92 | 85229 Markt Indersdorf | GermanyPhone: +49 8136 66-0 | Fax: +49 8136 [email protected]
See our worldwide sales service network atwww.hansenindustrialgearboxes.comwww.sumitomodrive.com
